Coating compositions and methods for application utilizing a high transfer efficiency applicator

A method of applying a coating composition to a substrate utilizing an applicator to form a coating layer disposed on the substrate, said method comprising the steps of:

• providing the coating composition to the applicator;
• applying the coating composition onto the substrate utilizing the applicator to form an applied layer with an application efficiency greater than 80%, wherein a loss of volatiles after application through the applicator is less than about 1 weight percent based on a total weight of the coating composition;
• performing a partial polymerization via radiation of the applied layer;
• and
• after performing the partial polymerization of the applied layer, thermally curing and drying the applied layer;
• wherein the coating composition comprises:
• a thermal binder;
• a radiation-polymerizable binder;
• optionally, a photo-initiator;
• optionally, a thermal-initiator;
• optionally, a pigment;
• and
• a liquid carrier;
• wherein the coating composition has a pre-application viscosity, at a shear rate of 1000 s−1, of less than about 100 centipoise (cP);
• wherein the coating composition has a post-radiation-exposure viscosity, at a shear rate of 0.1 s−1, of from about 500 cP to about 150,000 cP;
• wherein the thermal binder is a polymer or resin with crosslinkable groups selected from the group consisting of hydroxyl, acetoacetoxy, carboxyl, primary amine, secondary amine, epoxy and a combination thereof and crosslinking components selected from the group consisting of polyisocyanate, blocked polyisocyanate, polyamine, ketimine, melamine, epoxy, polyacid and a combination thereof.